Compact multi-material cut-off tool

ABSTRACT

A compact multi-material cut-off tool includes a housing, and an arbor rotatably supported by the housing upon which a cutting disk is attachable for co-rotation therewith. A motor is coupled to the arbor to provide torque thereto. A controller is operable to selectively drive the motor in a first rotational direction and an opposite, second rotational direction. A first lighting element is coupled to a first portion of the housing, and a second lighting element is coupled to a second portion of the housing. One of the first lighting element and the second lighting element is configured to be activated by the controller in response to the motor being driven in the first rotational direction. The other of the first lighting element and the second lighting element is configured to be activated by the controller in response to the motor being driven in the second rotational direction.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of co-pending U.S. patent applicationSer. No. 16/858,973 filed on Apr. 27, 2020, the contents of which isincorporated herein by reference.

FIELD OF THE DISCLOSURE

The present disclosure relates to power tools, and more specifically tocut-off tools.

BACKGROUND OF THE DISCLOSURE

Cut-off tools, such as multi-material cut-off tools, typically include ablade guard at least partially surrounding a cutting disk of the cut-offtool.

SUMMARY OF THE DISCLOSURE

The present disclosure provides, in one aspect, a cut-off tool includinga housing having a motor housing portion and a handle portion extendingtherefrom. An arbor is rotatably supported by the housing. A cuttingdisk is attachable to the arbor for co-rotation therewith. A motor ispositioned within the motor housing portion. The motor is coupled to thearbor to provide torque thereto. A blade guard surrounds an upperportion of the cutting disk. A first lighting element is positionedproximate an end of the handle portion that is opposite the motorhousing portion. A second lighting element is positioned on the motorhousing portion. The first lighting element is configured to illuminatea workpiece behind the cutting disk. The second lighting element isconfigured to illuminate the workpiece in front of the cutting disk.

The present disclosure provides, in another aspect, a cut-off toolincluding a housing including a handle portion and a battery receivingportion positioned adjacent the end of the handle portion. An arbor isrotatably supported by the housing. A cutting disk is attachable to thearbor for co-rotation therewith. A motor is positioned within thehousing. The motor is coupled to the arbor to provide torque thereto. Afirst lighting element is positioned on the battery receiving portion. Asecond lighting element is positioned on the housing and spaced awayfrom the first lighting element. The first lighting element isconfigured to illuminate a workpiece behind the cutting disk. The secondlighting element is configured to illuminate the workpiece in front ofthe cutting disk.

Other features and aspects of the disclosure will become apparent byconsideration of the following detailed description and accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a cut-off tool in accordance with anembodiment of the disclosure.

FIG. 2 is a side view of the cut-off tool of FIG. 1.

FIG. 3 is a cross-sectional view of the cut-off tool of FIG. 1 takenalong section 3-3 in FIG. 1.

FIG. 4 is a cross-sectional view of the cut-off tool of FIG. 1 takenalong section 4-4 in FIG. 1.

FIG. 5 is a flow chart illustrating a control process for activatinglighting elements of the cut-off tool of FIG. 1.

FIG. 6 is a flow chart illustrating another control process foractivating lighting elements of the cut-off tool of FIG. 1 based on arotational direction of a motor of the cut-off tool.

Before any embodiments of the disclosure are explained in detail, it isto be understood that the disclosure is not limited in its applicationto the details of construction and the arrangement of components setforth in the following description or illustrated in the followingdrawings. The disclosure is capable of other embodiments and of beingpracticed or of being carried out in various ways. Also, it is to beunderstood that the phraseology and terminology used herein is for thepurpose of description and should not be regarded as limiting.

DETAILED DESCRIPTION

FIGS. 1-4 illustrate all or portions of a cut-off tool, such as acompact multi-material cut-off tool 10. The cut-off tool 10 includes ahousing 14, a motor 18 (FIG. 4), and an arbor 22 driven by the motor 18to which a small diameter (e.g., 3 inch) cutting or grinding disk(hereinafter, “cutting disk 26”) is attachable. The motor 18 isrotatable in a first rotational direction (e.g., counter-clockwise fromthe frame of reference of FIG. 1) and an opposite, second rotationaldirection (e.g., clockwise from the frame of reference of FIG. 1)corresponding to a forward state and a reverse state, respectively, ofthe motor 18.

The housing 14 includes a motor housing portion 30. The motor 18 ispositioned within the motor housing portion 30. The housing 14 furtherincludes a handle portion 34 extending transversely from the motorhousing portion 30 and terminating in a battery receiving portion 38. Inparticular, the handle portion 34 extends between a first end 42 and asecond end 46 opposite the first end 42. The handle portion 34 defines alongitudinal axis 50 (FIG. 2) extending through the first and secondends 42, 46.

The motor housing portion 30 is adjacent the first end 42, and thebattery receiving portion 38 is adjacent the second end 46. The batteryreceiving portion 38 includes a multi-tier surface 54 facing toward themotor housing portion 30. The battery receiving portion 38 defines areceptacle 58 (FIG. 3) in which a battery pack 62 is received. Thebattery pack 62 is electrically connected to the motor 18 forselectively supplying power to the motor 18.

The cut-off tool 10 also includes a trigger 66 protruding from thehandle portion 34 of the housing 14. The trigger 66 is positionedproximate the motor housing portion 30 at the first end 42. The trigger66 is electrically connected to the motor 18. The trigger 66 ispositioned to permit a user to grasp the handle portion 34 formaneuvering the cut-off tool 10 (without an auxiliary handle) whiledepressing the trigger 66 to activate the motor 18.

The cut-off tool 10 further includes a forward/reverse selector switch(e.g., shuttle 70) located proximate the first end 42 of the handleportion 34. More specifically, the forward/reverse selector shuttle 70is located adjacent a front of the handle portion 34 and between themotor housing portion 30 and the trigger 66. The forward/reverseselector shuttle 70 is configured to determine the state of the motor18. More specifically, the forward/reverse selector shuttle 70 ismovable between a first position and a second position corresponding tothe forward state and the reverse state of the motor 18, respectively.The illustrated forward/reverse selector shuttle 70 is movable in adirection perpendicular to the longitudinal axis 50 of the handleportion 34. The forward/reverse selector shuttle 70 is positioned topermit the user to select either a forward or reverse rotationaldirection of the motor with their thumb, for example, while maintainingtheir grasp on the handle portion 34 with their index finger on thetrigger 66.

With reference to FIGS. 1-4, the motor housing portion 30 includes afirst end 74 and a second end 78 opposite the first end 74. A rotationalaxis 82 of the motor 18 extends through the first end 74 and the secondend 78 (FIG. 4). The rotational axis 82 is below the longitudinal axis50 of the handle portion 34 (i.e., from the frame of reference of FIG.3). The motor housing portion 30 further includes a generallycylindrical outer surface 86 extending between the first and second ends74, 78. The outer surface 86 includes a first side 90 facing away fromthe battery receiving portion 38. In addition, the motor housing portion30 defines a cavity 94 (FIG. 4) configured to receive the motor 18.

The motor 18 includes an output shaft 98 (FIG. 4) extending within thecavity 94 toward the second end 78 of the motor housing portion 30. Thearbor 22 of the cut-off tool 10 is coupled for co-rotation with theoutput shaft 98. The arbor 22 extends along the rotational axis 82 fromwithin the cavity 94 past the second end 78 of the motor housing portion30 to external of the motor housing portion 30. The cutting disk 26 isremovably attachable to an end of the arbor 22 that is external to themotor housing portion 30. In the illustrated embodiment, the cuttingdisk 26 is removably attachable by a retaining clip 102 (FIG. 4). Thecutting disk 26 is positioned proximate the second end 78 of the motorhousing portion 30.

With reference to FIGS. 1 and 2, the cut-off tool 10 includes an upperblade guard 106 supported on the motor housing portion 30. The upperblade guard 106 surrounds an upper portion of the cutting disc 26. Theupper blade guard 106 includes an adjustment mechanism 110. Theillustrated adjustment mechanism 110 includes a support member 114positioned at one end of the upper blade guard 106, and an attachmentmember or bracket 118 removably coupled to the support member 114 by anadjustment knob 116.

The cut-off tool 10 further includes a shoe 122 movably coupled to theupper blade guard 106. The illustrated shoe 122 includes a first,vertical portion 126, and a second, horizontal portion 130. The firstportion 126 is clamped between the bracket 118 and the support member114 of the upper blade guard 106. A vertical position of the bracket 118relative to the support member 114 is adjustable (e.g., by theadjustment knob 116) for adjustably coupling the shoe 122 to the upperblade guard 106. The second portion 130 is coupled to the first portion126 by a plurality of bends 138. The second portion 130 includes a firstleg 142 and a second leg 146 extending on either side of the cuttingdisc 26. Each leg 142, 146 is configured to contact a workpiece. Thecutting disk 26 is configured to extend through a gap defined betweenthe first and second legs 142, 146 when the cutting disk 26 is attachedto the arbor 22. The shoe 122 is movable relative to the upper bladeguard 106 in a vertical direction A (arrows; FIG. 2) that isperpendicular to the rotational axis 82 of the motor 18. Morespecifically, the shoe 122 is movable in the vertical direction Arelative to the upper blade guard 106 to permit adjustment of a cuttingdepth of the cutting disc 26.

With continued reference to FIGS. 1-2, the tool 10 includes a pluralityof lighting elements 150, 154 to illuminate a workpiece being cut by thetool 10. In the illustrated embodiment, the cut-off tool 10 includes afirst lighting element 150 and a second lighting element 154. Theillustrated first lighting element 150 is positioned on the batteryreceiving portion 38. More specifically, the first lighting element 150is positioned on the multi-tier surface 54 of the battery receivingportion 38 facing a second side 156 of the motor housing portion 30 thatis opposite the first side 90. The illustrated second lighting element154 is positioned on the first side 90 of the motor housing portion 30and proximate the cutting disk 26 (i.e., proximate the second end 78).

In some embodiments, each lighting element 150, 154 includes a lightemitting diode (LED) supported by the housing 14, and a lens overlyingthe respective LED. In addition, in some embodiments, the lightingelement 150, 154 is received in a respective receptacle defined by thehousing 14. The lens may cover the receptacle.

Each lighting element 150, 154 is configured to project a light awayfrom the cut-off tool 10 to illuminate an underlying workpiece duringcutting. More specifically, the first lighting element 150 is positionedon the battery receiving portion 38 below the longitudinal axis 50 ofthe handle portion 34. In addition, the first lighting element 150 isoriented to face toward the second side 156 of the motor housing portion30 such that the first lighting element 150 is oriented to face in afirst direction (i.e., to the left from the frame of reference of FIG.2). Further, the first lighting element 150 is positioned on an inclinedportion 56 of the multi-tier surface 54. The inclined portion 56 isoriented at an oblique angle relative to the axis 50 such that the firstlighting element 150 projects the light away from the surface 54 anddownward toward the workpiece being cut by the tool 10. As such, thefirst lighting element 150 is positioned to illuminate the workpiecebehind the cutting disk 26 (e.g., to the right of the cutting disk 26from the frame of reference of FIG. 2).

The illustrated second lighting element 154 is positioned on the firstside 90 of the motor housing portion 30 above the rotational axis 82 ofthe motor 18 (i.e., from the frame of reference of FIG. 1). In addition,the second lighting element 154 is oriented to face away from the motorhousing portion 30 such that the second lighting element 154 is alsooriented to face in the first direction (i.e., to the left from theframe of reference of FIG. 2). Further, similar to the first lightingelement 150, the second lighting element 154 is oriented at an obliqueangle relative to the axis 50 on the first side 90 such that the secondlighting element 154 projects the light away from the motor housingportion 30 and downward toward the workpiece being cut by the tool 10.As such, the second lighting element 154 is positioned to illuminate theworkpiece in front of the cutting disk 26 (e.g., to the left of thecutting disk 26 from the frame of reference of FIG. 2).

The cut-off tool 10 is configured to be moved (by a user) in both theforward direction (e.g., to the left from the frame of reference of FIG.2) and the rearward direction (e.g., to the right from the frame ofreference of FIG. 2) for cutting the underlying workpiece in both theforward and rearward directions. As such, the terms ‘in front of’ and‘behind’ recited above when describing illumination of the workpiecerelative to the cutting disk 26 are dependent upon the tool 10 moving ina forward direction during cutting. Alternatively, when the tool 10 isbeing moved to cut in a rearward direction by a user, the direction oflight of the first and second lighting elements 150, 154 may bedescribed as illuminating in front of the cutting disk 26 and behind thecutting disk 26, respectively. For example, when the tool 10 is beingmoved in a rearward direction by a user (e.g., to the right from theframe of reference of FIG. 2), the first lighting element 150 ispositioned to illuminate the workpiece in front of the cutting disk 26,(e.g., to the right of the cutting disk 26 from the frame of referenceof FIG. 2) and the second lighting element 154 is positioned toilluminate the workpiece behind the cutting disk 26 (e.g., to the leftof the cutting disk 26 from the frame of reference of FIG. 2). In otherwords, the first and second lighting elements 150, 154 are positioned toproject light on one side or the other, respectively, of the cuttingdisk 26, irrespective of the direction of movement of the cut-off tool10.

The cut-off tool 10 further includes a controller 166 (FIG. 3). Thecontroller 166 is electrically connected to the motor 18, the trigger66, the forward/reverse selector shuttle 70, and the plurality oflighting elements 150, 154. The cut-off tool 10 may also include asensor assembly (e.g., a Hall-effect sensor and magnet) electricallyconnected to the controller 166 for detecting actuation of the trigger66 and/or detecting a position of the forward/reverse selector shuttle70. The controller 166 is configured to determine actuation of thetrigger 66 by a user to control operation of the motor 18. In oneembodiment, as shown in FIG. 5, regardless of the position of theshuttle 70, both lighting elements 150, 154 are configured to activate(i.e., illuminate) simultaneously when the trigger 66 is actuated by auser. Accordingly, the workpiece is configured to be illuminated behindand in front of the cutting disk 26 during cutting, irrespective of thecutting direction of the tool 10 (forward or rearward).

In other embodiments, select lighting elements 150, 154 are configuredto activate based on a directional state of the motor 18. In thisconfiguration, the controller 166 is configured to determine a positionof the forward/reverse selector shuttle 70 for controlling activation ofthe select lighting elements 150, 154 based on the forward or reversestate of the motor 18. For example, as shown in FIG. 6, when theforward/reverse selector shuttle 70 is in the first position(corresponding to the forward state of the motor 18 to perform a cuttingoperation in the forward direction), only the second lighting element154 is configured to activate to illuminate the workpiece in front ofthe cutting disk 26. And when the forward/reverse selector slide shuttle166 is in the second position (corresponding to the reverse state of themotor 18 to perform a cutting operation in the rearward direction), onlythe first lighting element 150 is configured to activate to illuminatethe workpiece behind the cutting disk 26.

Various features of the invention are set forth in the following claims.

What is claimed is:
 1. A cut-off tool comprising: a housing including amotor housing portion and a handle portion extending therefrom; an arborrotatably supported by the housing; a cutting disk attachable to thearbor for co-rotation therewith; a motor positioned within the motorhousing portion, the motor coupled to the arbor to provide torquethereto; a blade guard surrounding an upper portion of the cutting disk;a first lighting element positioned proximate an end of the handleportion that is opposite the motor housing portion; and a secondlighting element positioned on the motor housing portion, wherein thefirst lighting element is configured to illuminate a workpiece behindthe cutting disk, and wherein the second lighting element is configuredto illuminate the workpiece in front of the cutting disk.
 2. The cut-offtool of claim 1, wherein the housing further includes a batteryreceiving portion positioned adjacent the end of the handle portion, andwherein the first lighting element is positioned on the batteryreceiving portion.
 3. The cut-off tool of claim 2, wherein the batteryreceiving portion includes a surface facing toward the motor housingportion, and wherein the first lighting element is positioned on thesurface.
 4. The cut-off tool of claim 1, wherein the motor housingportion includes an outer surface extending between a first end and asecond end of the motor housing portion, wherein the cutting disk isrotatably supported on the arbor adjacent the second end, and whereinthe second lighting element is positioned on the outer surface proximatethe second end.
 5. The cut-off tool of claim 1, further comprising acontroller operable to selectively drive the motor in a first rotationaldirection and an opposite, second rotational direction for selectivelyrotating the arbor and the cutting disk in the first rotationaldirection or the second rotational direction, respectively, and whereinone of the first lighting element or the second lighting element isconfigured to be activated by the controller in response to the motorbeing driven in the first rotational direction, and wherein the other ofthe first lighting element or the second lighting element is configuredto be activated by the controller in response to the motor being drivenin the second rotational direction.
 6. The cut-off tool of claim 5,further comprising a forward/reverse selector shuttle coupled to thehousing, wherein the forward/reverse selector shuttle is movable betweena first position and a second position corresponding to the firstrotational direction and the second rotational direction, respectively.7. The cut-off tool of claim 6, wherein the controller is operable todrive the motor in the first rotational direction or the secondrotational direction in response to the forward/reverse selector shuttlebeing in the first position or the second position, respectively.
 8. Thecut-off tool of claim 7, further comprising a trigger electricallyconnected with the controller to provide an input to the controller, andwherein, based on the input, the controller is configured to selectivelyactivate the motor and one of the first lighting element or the secondlighting element.
 9. The cut-off tool of claim 1, wherein the handleextends along a longitudinal axis, and wherein each of the firstlighting element and the second lighting element is oriented at anoblique angle relative to the longitudinal axis such that each of thefirst lighting element and the second lighting element is configured toproject light away from the housing and toward the workpiece being cut.10. The cut-off tool of claim 1, wherein the first lighting element ispositioned to illuminate the workpiece on one side of the cutting disk,and wherein the second lighting element is positioned to illuminate theworkpiece on an opposite side of the cutting disk.
 11. A cut-off toolcomprising: a housing including a handle portion and a battery receivingportion positioned adjacent the end of the handle portion; an arborrotatably supported by the housing; a cutting disk attachable to thearbor for co-rotation therewith; a motor positioned within the housing,the motor coupled to the arbor to provide torque thereto; a firstlighting element positioned on the battery receiving portion; and asecond lighting element positioned on the housing and spaced away fromthe first lighting element, wherein the first lighting element isconfigured to illuminate a workpiece behind the cutting disk, andwherein the second lighting element is configured to illuminate theworkpiece in front of the cutting disk.
 12. The cut-off tool of claim11, wherein the battery receiving portion includes a surface facingtoward the cutting disk, and wherein the first lighting element ispositioned on the surface.
 13. The cut-off tool of claim 12, wherein thesurface is a multi-tier surface, and wherein the first lighting elementis positioned on an inclined portion of the multi-tier surface.
 14. Thecut-off tool of claim 12, wherein the handle extends along alongitudinal axis, and wherein the surface is oriented at an obliqueangle relative to the longitudinal axis such that the first lightingelement is configured to project light away from the surface and towardthe workpiece being cut behind the cutting disk.
 15. The cut-off tool ofclaim 11, further comprising a controller operable to selectively drivethe motor in a first rotational direction and an opposite, secondrotational direction for selectively rotating the arbor and the cuttingdisk in the first rotational direction or the second rotationaldirection, respectively, and wherein one of the first lighting elementor the second lighting element is configured to be activated by thecontroller in response to the motor being driven in the first rotationaldirection, and wherein the other of the first lighting element or thesecond lighting element is configured to be activated by the controllerin response to the motor being driven in the second rotationaldirection.
 16. The cut-off tool of claim 15, further comprising aforward/reverse selector shuttle coupled to the housing, wherein theforward/reverse selector shuttle is movable between a first position anda second position corresponding to the first rotational direction andthe second rotational direction, respectively.
 17. The cut-off tool ofclaim 16, wherein the controller is operable to drive the motor in thefirst rotational direction or the second rotational direction inresponse to the forward/reverse selector shuttle being in the firstposition or the second position, respectively.
 18. The cut-off tool ofclaim 17, further comprising a trigger electrically connected with thecontroller to provide an input to the controller, and wherein, based onthe input, the controller is configured to selectively activate themotor and one of the first lighting element or the second lightingelement.
 19. The cut-off tool of claim 11, wherein the handle extendsalong a longitudinal axis, and wherein each of the first lightingelement and the second lighting element is oriented at an oblique anglerelative to the longitudinal axis such that each of the first lightingelement and the second lighting element is configured to project lightaway from the housing and toward the workpiece being cut.
 20. Thecut-off tool of claim 11, wherein the first lighting element ispositioned to illuminate the workpiece on one side of the cutting disk,and wherein the second lighting element is positioned to illuminate theworkpiece on an opposite side of the cutting disk.